2004 Sporty Help/Advice

Hi All,

Amazing forum you have set up, I can't believe how much I have picked up so far. I am VERY interested in picking up and installing a Stage 1 Kit and I have a few questions. I should describe my situation first. I picked up an 04 Sportster a couple years back, had SE air cleaner and V&H straightshots. The previous owner told me it had been jetted by the dealer. Last year I took it to another shop and was told the dealer didn't do anything right with the jet kit and that it needed to be adjusted, and I paid for it to be. Got the bike back, no real difference. It runs ok, but had a tendency to cough out if I crack the throttle from a stop or even if I rev up a bit to match RPM's when downshifting. I have no idea what jets are in there, or if the last shop drilled out the slide, etc. I am thinking about just purchasing a stage 1 kit w/ EZ-just; taking out the old jets, giving it a good cleaning and doing my best to adjust the idle/mixture. I also just installed an Arlen Ness big sucker stage II air kit (on clearance at the dealer, couldn't pass it up)

So my questions are:

1: Is the carb removal/breakdown a massive process that a person with average skill will find difficult?
2: What are the reviews on the stage 1 kit for the 04 Sporty 1200?
3: Could the coughing be due to something besides the jets, maybe an accelerator pump issue because it only does it from a stop or when cracking the throttle on a decel? And it is not a constant problem.

I only want to get the most out of the setup I have without installing an aftermarket carb/etc.

Thanks in advance for any help or advice, the site and forum are awesome.

So the here and there cough is probably the jets and/or enricher as opposed to something different like the accelerator pump? Anybody out there used this kit on the 1200?

Once I get the carb off the bike and broken down, is there any way I will know if the previous guy had the slide drilled out?

Sounds good. Thanks for all the help, I will let you know how the install goes. First time removing/disassembling the carb. Wish me luck.

Well... got the carb off the bike. Figured I would start early, my kit hasn't arrived yet, but it is a rainy day and there isn't anything better to do.

And inside, I found a notched needle (set on the 4th notch), 3 washers, a 170 main jet and a 48 idle. Not too mention, a 1/8" drill bit fits perfectly in the offset hole in the diaphragm slide.

Oh, and I can't seem to get the pin out on the float, so I can't get that off to clean.

Am I going to have to buy a new diaphram/sile?

Sporty - check the rubber if it's brittle or cracked then replace it. As for the float pin; it should slide out with no trouble, lift up on the float and try using a small punch or nail to get it started then just slide it out out. Be careful ya don't bend the float tab as it will affect the float position. To see if it's correctly adjusted -turn the carb upside down and rest it on a level surface then tip it 15 to 20 degrees toward the float - if the float closes you are there. HDMN88 shot me a PM and said to make sure you have the washers under the spring to start with and add them under the jet as needed. Ride it first to find out what it's doing and make adjustments as needed.
The 170 main jet should be just about right but like I said ride it first then make a call on changing it out.
One other item on the slide - look for wear on the ears, if gouged replace it. They only cost about $25.
Hope this helps.

Picked up a new slide at the dealer. The old one was drilled at least twice the size as stock.

As for the float pin... it's seriously stuck, not a chance at moving it, but the float appears to be operating just fine, so i'll leave it alone.

I'll have to look at the directions for the stage 1 kit when it gets here as to whether or not I'll need the washers.

Well, I came to find out that my kit did, in fact, get delivered today. Got her all put together, following all the steps. That rubber diaphragm was a bit tricky, hope it is seated ok. The slide seems to operate properly and is pushing air as it goes up and down.

Does anyone know how loose/tight the throttle & idle cables should be? I just adjusted them so there is a hair of slack when the throttle is closed, seems ok.

Last question, i hope When the EZ-just seats, gently, should I be able to see the tip of the pin sticking out of it's hole in the opening of the carb? It does not stick out at all when it is backed off 2 turns.

The kit and the help have been great. I'm going to try to tune everything up first thing tomorrow. Don't think the neighbors would appreciate me doing it at 1AM.

Attached a couple pics that I snapped with my phone. Keep the tips coming. Thank you guys for everything.

Well, tried to get it tuned this morning. Got warmed up with a couple laps around the neighborhood. The idle sounds fine, but I am having a real tough time getting the EZ-just to the right place.

I started at two turnes from bottom, bike ran rough and would cough out or backfire like a shotgun any time I blipped the throttle. So I started making turns out in 1/8" increments. Problem is still there and I am a full 3 turns from being bottomed. Also, when I ride, it is pretty rough on the decel. Need some tuning advice please.

Forgot to mention, when I blip the throttle and it coughs out... i get a big puff of black smoke out of the air filter. Too rich?? Maybe go back to 1 1/2 turns from bottom on the adjustment screw?

Took it back apart; tried to photo step-by-step.

It might take me a few posts

Part 2

And finally

Pulled the plugs; lots of soot. Dark black on the ceramic and white on the electrode tip. Rainy today so I couldn't take a test run and try to tune it up with the new plugs. Weather looks good for tomorrow.